VARsim is a VAR process simulator which incorporates operating parameters and furnace characteristics into electrode, arc, and ingot models to yield a tool suitable for simulating the VAR process from start to finish. Basic input data are expressed in terms of common operating parameters (voltage, current, arc gap, He pressure), heat-specific process parameters (electrode dimensions and weight, crucible dimensions) and furnace characteristics (resistance, water temperature and flow, etc). The use of default value boundary conditions, combined with menu-specified output parameters means that the model can be used by a process engineer having little to no modelling experience.
A template of a VARsim data file can be generated from within VARsim by selecting the Create Data Template button. This will display the following menu from which the desired units and major process characteristics can be selected. Other parameters will be generated automatically.
The resulting template will be applicable for melting a nominal 17 in (430 mm) diameter electrode of Alloy 718 into a nominal 20 in (510 mm) diameter crucible. A sample of a VARsim data file is displayed below. Once generated, such a data file may be edited within the Operating Parameter panel of VARsim, or with any text editor.
Parameters designated by a ‘-1’ invoke a default boundary condition which has been determined based on the simulation of a variety of test cases, but which can be over-written if the user has access to more accurate data.
Selection of desired output parameters will determine which output files are generated from the calculations. Several parameters will give rise to sub-menus to further select the desired output.
The latest version of VARsim has added a fluid flow module to aid in determining when operating parameters result in a condition that may be detrimental to ingot quality. This is not a full blown CFD model as is often described in current literature, but rather a model based on laminar flow subject to buoyancy and electromagnetic forces.
To download the latest version of VARsim (v 5.3.7) uploaded on 2025/11/01, please complete and submit the contact form below.